SUST Journal of Engineering and Computer Sciences (JECS), Vol. 20, No.

3, 2019

Study of High Pressure Heaters and Its Influence on Operation Cost in Power
Plants: Case Study Garri -4

Tariq O. Aburass 1, Yasser Nogoud 2, and Ahmed M. Osman Mohammed3

1
Department of Aeronautical Engineering, Faculty of Engineering, Karary University, [email protected]
2
Department of Aeronautical Engineering, Faculty of Engineering, Sudan University of Science and Technology;
[email protected]
3
Garri -4 Thermal Power Station; [email protected]

Received: 15/10/2019
Accepted: 17/11/2019

ABSTRACT-Electricity is one of the most important achievements that modern sciences have given to
mankind. It became a part of modern life and one cannot think of a world without it. It has many uses in our
daily life. Recently, in Sudan, there are some problems related to its continuity and availability of electrical
and thermal power generation. This paper presents a part of the solution for the generation of thermal power
for Garri-4. The characteristics of electrical energy are sustainability, easy transmission, and easy utilization.
All these factors make electrical energy desirable. The main problem of electrical power is the high cost of
production due to the high cost of fuel. Through the centuries, there is a lot of work done to reduce the energy
cost, by rising up the efficiency and increase the performance of the systems. This paper shows the effect of
high-pressure (HP) heaters out of service in the Garri-4 power plant. It aims to investigate the influence of HP
heaters on the power plant's overall performance. The mathematical modeling is used through thermodynamic
and heat transfer equations to study the efficiency and the operation cost for the power plant. The paper
concludes that HP heaters have a clear influence on the power plant performance by increasing the overall
power plant efficiency and reduce the operation cost. It also makes it less harmful to the environment through
less emission due to less fuel consumption. There is an increase the overall power plant efficiency by 3.78% ,
1.03%., and 2.56%, from 27.67%, for different cases studied in this paper.

Keywords: Thermal Power, High-Pressure (HP) Heaters, Heat Transfer, Heat Exchanger, Efficiency.

‫ وال يسكن التفكير فى الحياة الحديثة بدونها بددب األستخدامات الستعددة‬،‫ تعتبر الكهرباء من أهم مشجزات العمهم الحديثة لمبذر‬-‫ال ُم ْـس َــت ْخـلـَص‬
‫ برزت فى االونة األخيرة مذاكل تتعمق بإستسراية وإستدامة تهليد الطاقة الكهربائية فى الدهدان تتعمق بالتهليد السائى‬.‫لها فى األنذطة اليهمية‬
‫ سههلة‬,‫ من مسيزات الطاقة الكهربائية اإلستدامة‬.‫ هذه الدراسة تطرح جزء من الحمهل الستعمقة بالتهليد الحرارى لسحطة قرى الكهربائية‬.‫والحرارى‬
‫ تكسن مذكمة الدراسة في ارتفاع تكمفة انتاج الكهرباء من خالل‬.‫ كل هذه العهامل جعمت مشها الطاقة االكثر طمبا‬.‫الشقل وسههلة التعامل معها‬
‫ في هذه الدراسة تم‬.‫ سعي االندان عمي مر العرهر لتقميل تكاليف الطاقة من خالل رفع كفاءة االنظسة وتحدين أدائها‬.‫ارتفاع تكمفة الهقهد‬
‫التطرق الي سخانات الزغط العالي في محطة كهرباء قري الخارجة من الخدمة بهدف التحقق من تاثير سخانات الزغط العالي في رفع االداء‬
‫ أستخدم في هذه الدراسة الشسهزج الرياضي من خالل أستخدام معادالت الديشاميكا الح اررية وانتقال الح اررة لدراسة تأثير كفاءة‬.‫الكمي لمسحطة‬
‫خمرت الدراسة الي ان سخانات الزغط العالي لها تأثير وأضح عمي األداء الكمي لمسحطة من خالل رفع الكفاءة‬. .‫وتكاليف تذغيل السحطة‬
‫ وأيزا تقمل من االضرار السترتبة عمي البيئة عن طريق تقميل اإلنبعاثات من خالل تقميل إستهالك‬.‫ وتق ميل تكاليف التذغيل‬،‫الكمية لمسحطة‬
.‫الهقهد‬
1. INTRODUCTION are constantly made to improve the efficiency of
Throughout the century the man tried to reduce the the cycle on which steam power plants operate.
energy cost, by rising up the efficiency of the The general idea is to increase the fluid average
systems. Steam power plants generate most of the temperature during heat addition and decrease the
electric power in the world, to save fuel. Efforts fluid temperature during heat rejection [1].

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 SUST Journal of Engineering and Computer Sciences (JECS), Vol. 20, No. 3, 2019

Investigations on the increase of efficiency of the and condensate extraction pumps on the annual
Steam Turbine cycle and turbine production cost of the plant. Net present value reflects
concerns have been carried out by many Research equipment, maintenance, insurance, operating,
Centers for a few years. coal, and revenue increase with an increase in
The objectives of this paper are as follow; to pump redundancy in various subsystems. The Net
increase the efficiency of generation, to reduce the present value decreases with any addition of boiler
quantity of the fuel in order to increase the feed pump redundancy in the water circulation
operational life of a plant, to economically study subsystem. It also shows marginally increasing
the cost related to influence of high pressure trend with condensate extraction pump
heater, and to decrease (reduction) vibration in the redundancy in the condenser unit. The effect of
shaft of the turbine. condensate extraction pump redundancy on Net
The importance of the study lies in increasing the present value is comparatively higher as compared
generation efficiency (output increase from the with the case of the boiler feed pump. It is
turbine to the electric generator) is a cheap and expected to lower the initial cost of the condensate
safe manner. Also, it can supply the national grid extraction pump as compared with the cost of the
power capacity for sustained, stable electricity. It boiler feed pump.
is also significant in reducing the DC-stop from The usage of the high-pressure heater allows the
factories, homes, and hospitals which leads to the low temperature of condensate water to be
progress and development of Sudan [3]. pumped by the feedwater pump. It increases the
The Garri-4 power plant is a steam power plant. It lifetime of the feed water and maintains the power
uses the CFB boiler to generate steam. It also uses plant efficiency.
high-pressure heaters to improve the plant overall Another study conducted by Devandiran in 2016.
efficiency. It shows the effects of the feedwater heaters on the
Recently, the high-pressure heaters are out of performance of coal-fired power plants. By adding
service which led to erode the power plant the feedwater heaters in the power plant cycle, the
efficiency and increase fuel consumption. Other overall efficiency of the power plant is increased
related problems happened such as increase the by 2.4 %. Improving power plant efficiency could
turbine vibration. alleviate the negative effect of coal consumption
2. Studies that consider the influence of HP on CO2 emission. By means of thermodynamic
heater in the operating cost optimization.
The HP heater is found to reduce the power plant It was proposed to include the feedwater heaters in
cost through increasing the fuel utilization, by the power plant cycle, achieving optimum power
rising up the feedwater temperature before plant efficiency. Simulations had been carried out
entering the boiler. In the 210MWe coal-fired using HMBD software. Results showed a feasible
power plant which is situated in North India; improvement of the overall power plant efficiency.
Analysis is used to predict coal consumption This implied a direct reduction of Co2 emission of
rate, overall thermal efficiency, the mass flow about 1.3 %. Moreover, the financial analysis
rate of steam through the boiler, and Net confirmed the feasibility of the proposal analyzed
and showed the additional yearly incomes [2].
present value (NPV) of plant for a given load.
Another study conducted in Vijayawada Thermal
The thermodynamic analysis was carried out Power Station. It studied the parameters which
using mass and energy equations followed by directly or indirectly influence the performance of
empirical correlations, predicted mass flow the heater. The parameters include inlet
rate of steam, coal consumption rate. The temperature, saturation temperature, terminal tap
economic analysis included operational difference, drain cool approach and temperature
activities such as equipment cost, fuel cost, raise.
operations and maintenance cost, revenue, and The study concluded that the efficiency of the
plant net present value[1]. power plant increases with an increasing number
The study concluded that the effect of employing of heaters. It is not economical to have a large
redundancy (excessive) units to boiler feed pumps number of heaters to increase efficiency on the
basis of the techno-economic. The study of

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 SUST Journal of Engineering and Computer Sciences (JECS), Vol. 20, No. 3, 2019

numbers of heaters generally used in 210 MW conventional steam power plants or marine steam
units are 6 to 7. The efficiency increases by 5 to systems. Whereas, their operating parameters and
6% approximately, see Figure. 1. The operation behavior patterns differ greatly [5].
and maintenance of the heaters in the current The study considered the HP heater as shell and
power plant must be increased. There is no much tube heat exchanger used for waste heat recovery
deviation in the design and calculations values. It from the steam power plant. It represented a
is also observed that with this operation and mathematical model of high-pressure feedwater
maintenance the heaters are giving an efficiency of heater. The heater was divided into three zones de-
about 75% - 80% [3]. superheating, condensing and, sub-cooling for the
In this study which is written by Vedran Mrzljak modeling purpose. The same input parameters
[4]
, it analyzed the high-pressure feedwater heater, were given to the Aspen FRAN software and
as one of the essential components in the LNG results are obtained, Figure 2.
carrier steam propulsion system.

Figure 1: High-pressure feedwater heater energy

and energy efficiency change

Measurements of all operating parameters (fluid

streams) at the analyzed heat exchanger inlets and Figure 2: The effect of the tube length to the HP
outlets were performed. Changes of the operating heaters to rise in temperature
parameters were measured at different steam
system loads, not at full load as usual. Through The study concluded that the maximum amount of
these measurements were enabled insight into the heat duty is handled in the condensing zone of the
behavior of the heat exchanger operating feedwater heater. The Shell side heat transfer
parameters during the whole exploitation. The coefficient has a large influence on the overall heat
numerical analysis was performed, based on the transfer coefficient and hence area of the
measured data. feedwater heater.
The changes in energy and energy efficiency of The Fouling factor effects in the calculation of
the heat exchanger were analyzed. Energetic and surface area to a large extent. Condensing zone
energetic power inputs and outputs were also accounts for the maximum amount of area of
calculated, which enabled an insight into the feedwater heater than the other two zones. The
change of energetic and energetic power losses of pressure drop on the shell side was maximum in
the heat exchanger at different steam system loads. the sub-cooling zone as compared to the other two
Changes in energetic and energetic power losses zones while the pressure drop on the tube side of
and operating parameters have the strongest the feedwater heater is negligible [6].
influence on the high-pressure feedwater heater A.A.A.Abuelnuor, et al.,2017 give an exergy
losses were described. analysis of Garri “2” 180 MW combined cycle
The analyzed heat exchanger was compared with power plant. the results proved that combustion
similar heat exchangers in the base loaded chambers are the main sources of exergy
conventional steam power plants. From the destruction due to their high irreversibility [7].
conducted analysis, it was concluded that the Abuelnuor A. A. Abuelnuor, et al.,2019
adjustment and control modes of these high- emphasizes that exergy analysis is useful in
pressure heat exchangers are equal, regardless of determining irreversibilities and losses in
whether they were mounted in the base loaded

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 SUST Journal of Engineering and Computer Sciences (JECS), Vol. 20, No. 3, 2019

Elroseires hydropower plant to improve its plant, wastewater treatment plant, cooling towers,
thermodynamic performance [8]. circulating water pumps house.
LDO storage tank and pump house, sponge coke
3. Heat Exchanger Model shed, convey system. There are an auxiliary boiler
Heat exchangers are devices used to transfer heat and emergency generator house, administration
between a solid object and a fluid, or between two building, and Workshop. Table 1 explains the
or more fluids. The fluids may be separated by a main technical parameters of the turbine unit [8].
solid wall to prevent mixing or they may be in 3.4 High pressure (H.P) heater model in Garri4
direct contact [9]. power plant
The utility of H.P heater is to use the extract-steam
3.1 Garri4 Power Plant Steam
from the turbine to heat the feed water of the
It is a first power plant in the Middle East that
boiler to reach the required temperature. The
used solid fuel (sponge coke). This coke can be
process can increase thermal efficiency.The H.P
used to generate electric power. Garri-4 is a steam
heater of the 55MW turbine is installed vertically.
power plant. It works with the regeneration cycle.
The U tube bundle is assembled. It has two zones
It consists of two steam turbines each one
de-superheating zone and condensing zone. The
generates 55 MW. Each turbine has a boiler to
H.P heater has the small feedwater bypass system
supply superheated steam to the turbine. This
with (1) set of inlet/ outlet feed-water valve for
boiler is known as a Circulating Fluidized Bed
each H.P heater.
Boilers (CFB Boilers).

TABLE 1: MAIN TECHNICAL PARAMETER OF TURBINE 4. Mathematical Modeling

UNIT
[10] The mathematical modeling follows the
No Technical Parameter Value thermodynamics equations, mass and heat transfer
1 Rated power 55MW equations. The heat balance principle used to
2 Maximum power: 62MW calculate the power produced by the turbine as
8.83± well as the power consumed by pumps.
3 Rated pressure of main steam
0.49MPa The actual operating characteristic is collected
4
The rated temperature of main
535 ºC 510+−
during the operation of the power plants at various
steam loads. They are used in the calculation to find out
5 Exhaust steam pressure: 11.80 a the overall power plant performance
6 Rated main stream flow 219.5t/h characteristics for both when they operate with HP
7 Maximum main stream flow 252T/H heaters and without HP heaters. Figure .4; explains
8 Rotating speed 3000r/min the P&ID sketch for the garri-4 power plant.
33ºC(max.38
9 Cooling water temperature
ºC ）
10 Feedwater temperature 234 ºC
11 Heat consumption 9823.8kJ/kWh
3.987
12 Steam consumption
Kg/KW.h
13 Rated steam flow 219.5 t/h
19 stages in
14 Flow path stages
total
One governing stage adds 18
15 -
pressure stages
16 2 HP heaters and 3 LP heaters -

3.2 The layout of Garri4 Power Station

The layout of the station as follows; it has two
CFB boilers, the main power building which
contains two steam turbines with generators and Figure 4: P&ID sketch for garri-4 power plant
auxiliary equipment’s, substation, clarified water
tank, composite pump house, demineralization

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 SUST Journal of Engineering and Computer Sciences (JECS), Vol. 20, No. 3, 2019

4.1 Equation used in Calculations CV sk : Sponge coke calorific value (36000KJ/Kg).

Calculations use mathematical equations and
 : The overall efficiency of the power plant.
thermodynamic laws in studying the effect of
high-pressure heat exchangers in efficiency and 4.2 Sample Calculation model for 55Mw
cost [9][11]. When high-pressure heaters in service the
 The Turbine Power: following values are calculated in Table. 2.

W T  m1 ( h1  h2 )  ( m1  m 2 )( h2  h3 ) 
5. Results and Discussions
( m1  m 2  m 3 )( h3  h4 )  The influence of high-pressure heater into the
( m1  m 2  m 3  m 4 )( h4  h5 )  Garri-4 power plant is discussed in terms of
( m1  m 2  m 3  m 4  m 5 )( h5  h6 )  efficiency and operation cost. There are four
( m1  m 2  m 3  m 4  m 5  m 6 )( h6  h7 )  models used to evaluate the influence of HP
( m1  m 2  m 3  m 4  m 5  m 6  m 7 )( h7  h8 ) heaters when they are both in service, and when
(1) HP heater no 1 or no 2 out of service.
The overall power plant performance calculated
 The Pump power: for different operation conditions, at different
loads 55, 44, 33, and 22 MW. The HP heaters
W p  ( m 1  m 2  m 3  m 4 )( h 9  h10 ) 
operation status is also considered in calculations.
There are four models of study used to calculate
m 1 ( h18  h17 ) the power plant performance as follow:
(2)
TABLE 2: CALCULATION MODEL FOR 55MW [9][11]
 The net of mechanical power:
No: Technical Parameter value
W net W T W p (3) A. When high-pressure heaters in service
 The heat supplied: 1 The turbine power wT 56125.9 kW
2 The Pump power WP 1324.0 kW
Qin  m sk CV sk (4)
The net of mechanical
 The overall efficiency of the power plant: 3 54801.9 kW
power
w net 4 The heat supplied 174000.000 kW.
 (5) The overall efficiency of
Q in 5
the power plant
31.5%
where: 6 Price per hour 5585.4 SDG
w T : The Mechanical Power of Turbine (kW). B. When high-pressure heaters out of service
190.6 ton/hr
hn : The specific enthalpy at the point n (KJ/Kg). 7 Main stream flow m1
(m2 and m3=0)
m1 : The main steam mass flow rate (kg/s). Sponge coke
8 19.8ton/hr
consumption
m2 : The 1st bleeding mass flow rate (kg/s). The turbine power wT 56125.2 kW.
9
m3 : The 2nd bleeding mass flow rate (kg/s). 10 The Pump power WP 1201.527 kW
The net of mechanical
m4 : The 3rd bleeding mass flow rate (kg/s). 11 54923.67 kW
power
m5 : The 4th bleeding mass flow rate (kg/s). 12 The heat supplied 198000.000 kW
The overall efficiency of
m6 : The 5th bleeding mass flow rate (kg/s). 13 27.74%
the power plant
m7 : The 6th bleeding mass flow rate (kg/s). 14 Price per hour 6355.8 SDG
w p : The power consumed by the pumps (kW).
 study of power plant performance when both HP
Q in : The heat rate supplied by the boiler (kW).
heaters in the service.
m sk :Mass flow rate supplied by sponge coke  study of power plant performance when the HP
(kg/s). heater no 1 is out of service.
W net : The net of mechanical power (KW).  study of power plant performance when the HP
heaters no 2 is out of service.

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 SUST Journal of Engineering and Computer Sciences (JECS), Vol. 20, No. 3, 2019

 study of power plant performance when both HP (1) in-service up to 4650 SDG/hr, and decreased
heaters are out of service. cost when HP heater (2) in-service to 4898 SDG.
5.1 The overall power plant efficiency and It also decreases to 4463 SDG/hr if both heaters in
operation cost at 55 MW service.
As shown in Figure. 5, when HP heaters are out of
service is 27.74%. It’s increased by 3.76% when
the HP heater in service. It is also increased by
1.03% if HP heater no (1) in-service, and also
increased by 2.55% if HP heater no (2) in service.
Also, the effect of HP heaters obviously can be
shown in figure. 6, when HP heater is out of
service the cost 6356 SDG/hr, that it’s decreased
when HP heater1# in service up to 5812SDG/hr. It
decreased cost when HP heater2# in service to
6123 SDG, and also decreased to 5585 SDG/hr if
both of heaters in service.
Figure 7: The overall power plant efficiency for 44
MW.

Figure 5: The overall power plant efficiency for 55

MW. Figure 8: The cost SDG per hour, for 44 MW.

5.3 The overall power plant efficiency and

operation cost at 33 MW
As shown in figure.9, when HP heater is out of
service it represents 27.68%. It is increased by
3.76% when the HP heater in service. It is
increased by 1% if HP heater no 1 in service, and
also increased by 2.55% if HP heater no (2) in
service.

Figure 6: The cost SDG per hour, for 55 MW.

5.2 The overall power plant efficiency and

operation cost at 44 MW
As shown in figure.7, when HP heater is out of
service it represents 27.67%, that it is increased by
3.8% when the HP heater in service. It is increased
by 1.02% if HP heater no 1 in service, and also
increased by 2.58% if HP heater no 2 in service.
The effect of HP heaters obviously shown in the Figure .9: The overall power plant efficiency for 33
figure.8, when HP heater is out of service the cost MW.
is 5085 SDG/hr. it is decreased when HP heater

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 SUST Journal of Engineering and Computer Sciences (JECS), Vol. 20, No. 3, 2019

The effect of HP heaters obviously can be shown

in figure.10. When HP heater is out of service the The effect of HP heaters obviously can be shown
cost is 3810 SDG/hr. It is decreased when HP in the figure 12, when HP heater is out of service
heater (1) in-service up to 3487 SDG/hr. It is the cost 2542 SDG/hr. It is decreased when HP
decreased cost when HP heater (2) in-service to heater (1) in-service ups SDG/hr. And decreased
3674 SDG, and also decreased to 3351 SDG/hr if cost when HP heater2# in service to 2449 SDG,
both of heaters in service. and also decreased to 2234 SDG/hr if both of
heaters in service.

6. Discussion
The results show the effect of high-pressure heat
exchangers in the Garri-4 power plant has been
calculated. The study found that the efficiency of
the second HP heater is greater inefficiency
because it is closer to the place of attrition. The
HP heaters no1 and no 2 together have a good
performance increasing efficiency and decrease
the cost.
Figure.10: The cost SDG per hour, for 33
The presence of HP heater exchangers in the
MW.
service also reduces the risk of vibrations in the
5.4 The overall power plant efficiency and
shaft of the turbine.
operation cost at 22 MW
The metal temperature of the boiler tube reduces
As shown in figure 11, when HP heater is out of
service it represents 27.60%. It is increased by by taking feed heaters in service and hence
increases the boiler tube life and reduces the
3.79% when the HP heater in service. It is
increased by 1.05% if HP heater no (1) in-service, outage due to tube leakages.
and also increased by 2.58% if HP heater no (2) in When the HP heater is out of service there is some
steam drained to maintain some operational
service.
conditions. It is considered a loss of opportunity
cost of power generation. It is also considered the
loss of fuel that added in early steam generation.
The HP heater does not put in service at a lower
load due to the high difference in temperature
between the bleeding steam and the feed water.
This causes the thermal stresses in heaters so that
the bleeding no2 can be used for both deaerator
and HP heater no2. It allows small different
between feed water and bleeding steam. The plant
in high load with both HP heaters no1 and no2 to
Figure. 11: The overall power plant increase the efficiency and decrease the quantity
efficiency for 22 MW. of the fuel. It reduces the operation cost, where the
increase the lifetime of the power plant through
optimizing the use of the boiler and turbine
utilities.

7. Conclusions and Recommendation

The study concluded that, to put the HP heaters in
service, increase the overall power plant efficiency
by 3.78% from 27.67%, and when HP heater no1
in service it is increased by 1.03%. When HP
heater no 2 in service it is increased by 2.56%,
Figure 12: The cost SDG per hour, for 22 MW where the efficiency of the power plant without

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 SUST Journal of Engineering and Computer Sciences (JECS), Vol. 20, No. 3, 2019

HP heaters is 27.67%. Also, a little bit increased 9873.1000308Research ArticleOpen AccessJournal

inefficiency with the increase in the load. The cost of Applied Mechanical Engineering, Vol. 7, No. 3.
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The decrease in efficiency means the chance of Regenerative Feed Water Heaters on the
Operational Costs of Steam Power Plants" Int. J. of
more fuel consumption. This increases the number
Thermodynamics, Vol. 8, No. 3.
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When the HP heaters are out of service, the "Thermodynamical Analysis of High - Pressure
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Nogoud, Y.A.M., Babiker, M.E.A.M, (2019 )
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